A fire resistant panel, a system of said panel and installation means, assemblies comprising said panels and methods of production and assembly thereof

Abstract

The present invention belongs to the field of construction materials, more precisely to construction panels resistant to fire. The invention relates to a fire resistant panel, a system of said panel and installation means, as well as to assemblies comprising said panels and methods of production and assembly thereof. The fire resistant panel comprises a top plate, a bottom plate, panel fill made from any suitable material, which is provided between the top and the bottom plate, wherein the thickness of the fill is at least 50 mm to allow suitable carrying capacity of 250kg / m2, and wherein all of the above components are glued together with a suitable glue and additionally screwed together with suitable screws around the entire perimeter on side of panel and both plates, at least every 500 mm. The panel further comprises a side fire-resistant sealing provided around the entire perimeter on side between said plates, a frame made from a curved stainless steel, provided around the entire perimeter, wherein the cross-section of the frame has a shape of letter U and comprises reinforcements at least every 600 mm and around any possible openings for installation of lights, installations, sensors and / or other elements, wherein said reinforcements are made from stainless steel, and corner joints provided at every corner, wherein said corner joints are made from curved stainless steel.

Description

Field of the invention

[0001] The present invention belongs to the field of construction materials, more precisely to construction panels resistant to fire. The invention relates to a fire resistant panel, a system of said panel and installation means, as well as to assemblies comprising said panels and methods of production and assembly thereof.Background of the invention and the technical problem

[0002] Fire resistant panels are used for a wide range of external façade cladding, internal partition walls, fire walls and ceilings for either leisure, commercial, industrial, hygienic and other facilities. Such panels are widely produced by various manufacturers, such as Trimo Trebnje (https: / / www.trimo-group.com / en / products / facades-and-walls / trimoterm; All Weather Insulated Panels (https: / / www.awipanels.com / product-categories / fire-panels / ), Armstrong ceilings (https: / / www.armstrongceilings.com / commercial / en / performance / fire-resistant-ceilings.html) and Durlum (https: / / www.durlum.com / en / products / metal-ceilings / functional-ceilings / dur-f30r-fire-resistant-ceilings / dur-f30r-easy-click). For example, Trimo has panels made from sheet metal and mineral wool, wherein no frame is used.

[0003] In addition to fire resistance panels used for ceilings have to exhibit suitable carrying capacity. There are several standards in this field, however, the R30 and R60 classes of the EN 13501-2:2016 relate to suitable carrying capacity under load and fire. Panels fulfilling the provisions of these two standards remain unaffected for 30 or 60 minutes, respectively, and the ceiling built with such panels does not collapse.

[0004] It is the aim of the present invention to provide panels of suitable fire-resistance according to above-identified standards as well as systems of panels and mounting (installation) means for building ceilings with suitable carrying capacity of at least 150 and up to 250 kg / m 2< . A further aim of the invention is to provide structures for ceilings and walls using said panels and installation means.Prior art

[0005] Patent application JPH10252180 relates to a fireproof wall structure of building and interior wall panel. According to this solution an exterior wall panel is provided with waterproof, wind resistant, fire shielding function and the like constituted of hard wood piece cement and the like attaches an attaching muntin to the floor beam and the like of a building unit. An interior wall panel is provided with fireproof, heat insulating and soundproof function sticking plaster boards and a rock board on both the sides of a steel frame, lower and upper horizontal muntins are attached to floor face material and ceiling face material. A fireproof non-vulcanized rubber sheet is stuck on a part attaching the exterior wall panel to a floor beam, a column and a ceiling beam. The construction of panels and their installation systems differ from the present invention.

[0006] Patent application JP2010127012 describes a partition wall structure. The partition wall structure includes a plurality of substrate panels erected between an upper rail and a lower rail respectively fixed to a ceiling and a floor face along a wall core. The substrate panel is formed by bending a long-sized steel plate into a hat shape, wherein the width of a head of the hat shape is narrower than the width of the bottom side so as to incline the side face while having a cross-section shape of a trapezoid groove in the head of the hat shape. The heads of the substrate panels are alternately arranged to both outer side directions in a zigzag way and a sound insulation material is interposed between the side faces on both ends of the adjacent substrate panels to form a partition wall substrate along a panel-wall core. A board is fixed to the head of the substrate panel by a screw or the like. The present invention differs from this disclosure in the construction of the panels.

[0007] Patent GB2509000 discloses a fire resistant structure such as a firewall or ceiling, wherein the structure comprises a number of frame units attached together to form a substructure of the fire resistant structure and a number of fire resistant panels arranged to clad the sub structure / framework so as to provide a fire-facing face of the substructure. The panels substantially cover a front face of each frame unit. The structure may be clad on the front and a rear face of the units and define a hollow zone between the front and rear faces. The panels may comprise an endothermic reacting insulating fibrous material. The frame unit may be made from steel and include a number of apertures or holes to reduce heat build up or receiving fasteners to attach one of the panels to the unit. The structure may include gaskets which substantially cover the end faces of a frame unit and located between adjacent frame units to retard / restrict heat transfer between units. Albeit this solution has a similar material for the panel frame, it has a different shape and installation means.

[0008] Patent application GB1117811 discloses a panel comprising a glass mat reinforced polyester resin containing coloured filler, aggregate and sand, a perforated asbestos panel, a metal frame made of 'L' and 'U'-section perforated steel sections and a facing of heat-insulating material e.g. mineral wool or glass-fibre quilting. Timber studding which is held in place at floor and ceiling levels and plaster board sheet nailed to the studding being applied on site. In making a unit, the perforated asbestos board with framing attached by stud and nut fastenings is partially embedded in the web resin lay up, the metallic frame removed, a layer of resin and a glass fibre mat applied to the board and the framing replaced. The panels are connected together in assembling the building by nuts and bolts inserted through adjoining parts of the metal frames, the adjoining parts being separated by a steel pad and the joints sealed by sealing, grouting or jointing material. The present invention differs in the mounting as well as frame design.

[0009] Patent FR2370835 describes a fire resistant suspended ceiling comprising insulation filled flanged panels supported by grid with tabs passing through slits along flanges. A fire resistant suspended ceiling has a support grid made of angle or channel members of stainless steel sheet, carrying dished stainless steel panels. Two angles mounted back to back have sloping arms projecting from them with parts of their top edges extending above the vertical flanges of the angles. These pass through slots through the horizontal flanges of the sides of the panels. This forms a securing system which does not require screws, bolts, clips or other extra fastenings. Each panel can be filled with a light weight refractory material such as fibre filled cement, or mineral fibre or wool.

[0010] Patent FR2349697 relates to fire resistant ceiling construction, which has several steel space trusses arranged to form rectangular space grid ceiling construction. The fire resistant space grid ceiling system comprises a number of steel space trusses arranged to form a rectangular space grid ceiling construction, the trusses having base members with opposite horizontally outwardly extending flanges and rectangularly shaped fire resistant ceiling panels supported on their opposite edges on top of the flanges in spanning relationship to adjacent base members and leaving exposed beneath it a lower portion of the base members. Rectangularly shaped, fire resistant grid protecting panels have a width the same as the width of the exposed portion of the base members and are secured to the underside of the flanges of the base members and separate elongate channel members have a vertical wall with top and bottom edges and horizontal top and bottom walls on the top and bottom edges of the vertical wall. This solution differs from the present invention.

[0011] Currently known solutions do not exhibit the required carrying capacity as defined in the above-mentioned standards, hence, the invention aims to solve these disadvantages.Description of the solution to the technical problem

[0012] The present invention addresses the problem of providing panels and systems for building ceilings as well as walls fulfilling conditions for R30 and R60 classes of the EN 13501-2:2016. The technical problem is solved as defined in the independent claim, wherein preferred embodiments are defined in dependent claims.

[0013] The fire resistant panel according to the invention comprises: a top plate, preferably made from aluminium sheet, optionally chromated or RAL powder coated particularly if used for clean rooms, a bottom plate, preferably made from aluminium sheet, optionally RAL powder coated, panel fill made from any suitable material, preferably made from mineral wool, which is provided between the top and the bottom plate, wherein the thickness of the fill is at least 50 mm to allow suitable carrying capacity of 250kg / m 2< , wherein all of the above components are glued together with a suitable glue and additionally screwed together with suitable screws around the entire perimeter on side of panel and both plates, at least every 500 mm, a side fire-resistant sealing, preferably an expansion tape, provided around the entire perimeter on side between said plates, a side sealing, preferably EPDM Foam, provided around the entire perimeter on side 3 mm from top and bottom of panel, wherein during installation of the panels silicone is provided between the panels to seal the openings and gaps between the panels to ensure water or moisture does not reach the fill material, wherein the silicon is resistant to chemicals and shows antibacterial properties, and wherein the panel further comprises: a frame made from a curved stainless steel, provided around the entire perimeter, wherein the cross-section of the frame has a shape of letter U, preferably having a thickness of the frame wall of 1 mm, and wherein said frame comprises: reinforcements at least every 600 mm and around any possible openings for installation of lights, installations, sensors and / or other elements, wherein said reinforcements are made from stainless steel, preferably shaped as the frame (U-shaped cross-section, thickness of 1 mm), wherein the reinforcements are suitably attached to the frame in any known manner, preferably with corner joints, corner joints provided at every corner, wherein said corner joints are made from curved stainless steel.

[0014] A further aspect of the invention is a system of the panel as described above and installation means for installation of panels as a hanging ceiling, wherein the installation means are aluminium holders installed in pairs around every corner and side carriers made from stainless steel arranged along each side of the panel frame.

[0015] A method of production of the fire resistant panel comprises the following steps: a) providing a first and a second aluminimum plate with preferred thickness of 1.2 mm cut in the required dimension, wherein each plate is optionally chromated or coated with RAL powder, b) providing a U-shaped frame made from bent stainless steel strips and provided with reinforcements and corner joints, c) application of glue to one surface of the first aluminium plate, d) placement of the prepared frame onto the glued surface of the first aluminium plate, e) inserting the filling material, wherein the lowermost part is filled first and then sequentially followed by each higher part, and wherein the filling material is preferably cut in three or four parts and each part is first provided with side ends and then centre parts, f) application of glue to one surface of a second aluminium plate with preferred thickness of 1.2 mm cut in the required dimension, wherein each plate is optionally chromated or coated with RAL powder, g) placement of the glued surface of the second aluminium plate on the frame, h) pressing the prepared panel in a press with spacers installed at the desired height to ensure suitable panel thickness, wherein the press operates for at least 20 minutes at pressure exponentially increasing from 0 to max 25 barscrewing together the frame and both plates with suitable screws around the entire perimeter on side of panel and both plates, at least every 500 mm, i) providing an expansion tape around the entire perimeter on side between said plates.

[0016] A plurality of panels and / or a plurality of systems as described above can be assembled into various structures, such as ceilings, hanging ceilings, ceilings for clean rooms, as well as walls, partition walls, and similar structures. The number of panels is arbitrary and depends on the size of the required structure, dimensions of the panels, and other factors. Adjusting the number of panels and / or systems is obvious to the skilled person based on the building project.

[0017] An additional aspect of the invention is also a method for installation of fire resistant panels into the assembly, wherein said method comprises the following steps: combining a plurality of panels onto a suitable carrying frame, providing and installing suitable installation means, and providing silicone in gaps between all plates, wherein the silicone is resistant to chemicals and antimicrobial, to ensure stable protection of the panel filling.

[0018] In case the assembly is a ceiling, the method for installation comprises the following steps: i. providing a plurality of panels as described above, ii. installation of aluminium hangers at dedicated positions, iii. installation of side hangers at dedicated positions, iv. providing EDPM on sides of one panel on top and bottom v. combining a plurality of panels onto a suitable carrying frame using the installed hangers, vi. providing silicone in gaps between all plates, wherein the silicone is resistant to chemicals and antimicrobial, to ensure stable protection of the panel filling.

[0019] The invention as described above solves the technical problem as tests according to standards SIST EN 13501-2:2016 have shown that the panels belong to fire-class resistance class R60. A ceiling made from said panels with installation means loaded with 250 kg / m 2< endures a fire for at least 60 minutes from below at temperatures ranging from 23 to 946 °C reached after 60 minutes without any deflections, deformations or other failure. The temperature was measured at 7 different points in the furnace used for ensuring fire-like conditions.Brief description of the drawings

[0020] The invention will be described in further detail based on exemplary embodiments and figures, which show: Figure 1A cross-section of the panel according to a possible embodiment Figure 2aFrame according to a possible embodiment Figure 2bA corner element according to a possible embodiment Figure 3Installation process for the fill material Figure 4aAluminium holder Figure 4bSide holder Detailed description of the invention

[0021] The fire resistant panel as shown in figure 1 comprises: a top plate 2 made from aluminium sheet, which is chromated or RAL powder coated, a bottom plate 2' made from aluminium sheet coated with RAL powder, panel fill 4 made from mineral wool, which is provided between the top and the bottom plate, wherein the thickness of the fill is 50 mm, wherein all of the above components are glued together with a suitable glue and additionally screwed together with suitable screws 6 around the entire perimeter on side of panel and both plates 2, 2', at least every 500 mm, a side fire-resistant sealing 5, preferably an expansion tape, provided around the entire perimeter on side between said plates, a side sealing from EPDM foam 7, provided around the entire perimeter on side 3 mm from top and bottom of panel, a frame 1 made from a curved stainless steel, provided around the entire perimeter, wherein the cross-section of the frame has a shape of letter U as shown in figure 2a, preferably having a thickness of the frame wall of 1 mm, and wherein said frame comprises: reinforcements at least every 600 mm and around any possible openings for installation of lights, installations, sensors and / or other elements, wherein said reinforcements are made from stainless steel, preferably shaped as the frame (U-shaped cross-section, thickness of 1 mm), wherein the reinforcements are suitably attached to the frame with corner joints, corner joints 3 (as shown in figure 2b) provided at every corner, wherein said corner joints are made from curved stainless steel.

[0022] The method of production of the fire resistant panel shown in figure 1 comprises the following steps: a) providing a first and a second aluminimum plate 2, 2' with thickness of 1.2 mm cut in the required dimension, wherein each plate is chromated or coated with RAL powder, b) providing a U-shaped frame 1 made from bent stainless steel strips and provided with reinforcements and corner joints, c) application of glue to one surface of the first aluminium plate 2, d) placement of the prepared frame 1 onto the glued surface of the first aluminium plate 2, e) inserting the mineral wool as the filling material 4, f) application of glue to one surface of a second aluminium plate 2' with preferred thickness of 1.2 mm cut in the required dimension, wherein each plate is chromated or coated with RAL powder, g) placement of the glued surface of the second aluminium plate 2' on the frame 1, h) pressing the prepared panel in a press with spacers installed at the desired height to ensure suitable panel thickness, wherein the press operates for at least 20 minutes at pressure exponentially increasing from 0 to max 25 bar, i) screwing together the frame and both plates with suitable screws 6 around the entire perimeter on side of panel and both plates 2, 2', at least every 500 mm, j) providing an expansion tape 7 around the entire perimeter on side between said plates.

[0023] Figure 3 shows the process of installation of the filling material in step e), wherein the lowermost part is filled first (indicated by the letter a) and then sequentially followed by each higher part indicated by letters b, c, d and e, and wherein the filling material is preferably cut in three or four parts and each part is first provided with side parts A1 and then a centre part A2.

[0024] A plurality of panels and / or a plurality of systems as described above can be assembled into various structures, such as ceilings, hanging ceilings, ceilings for clean rooms, as well as walls, partition walls, and similar structures. The number of panels is arbitrary and depends on the size of the required structure, dimensions of the panels, and other factors. Adjusting the number of panels and / or systems is obvious to the skilled person based on the building project. During installation of the panels silicone is provided between the panels to seal the openings and gaps between the panels to ensure water or moisture does not reach the fill material, wherein the silicon is resistant to chemicals and shows antibacterial properties,

[0025] The method for installation of fire resistant panels into a ceiling comprises the following steps: i. providing a plurality of panels as described above, ii. installation of aluminium hangers as shown in figure 4a at dedicated positions shown in figure 4c, iii. installation of side hangers shown in figure 4b at dedicated positions indicated in figure 4c, iv. providing EDPM on sides of one panel on top and bottom, v. combining a plurality of panels onto a suitable carrying frame using the installed hangers, and vi. providing silicone in gaps between all plates, wherein the silicone is resistant to chemicals and antimicrobial, to ensure stable protection of the panel filling.

[0026] The aluminium hanger 9 (shown in figures 1 and 4b) is shaped as a plate with a rectangular part and a semicircular part, wherein the bottom of the rectangular part is provided with holes for installation and the semicircular part is in the middle provided with an opening for installation. The side hangers 8 shown in figures 1 and 4a are similar in shape, however, they are bent for 90 degrees at approximately one half of the height of the rectangular part indicated by the arrow. A horizontal part and a vertical part are thus created, wherein the horizontal part is provided with a plurality of holes for installation and the vertical part shaped as a semi-circle is in the middle provided with an opening for installation. The expansion tape is for the installation of side hangers removed at suitable places, the hangers are then screwed in place and the expansion tape is once more provided over the hangers.

[0027] At least 8 aluminium hangers are used for each panel, at least 2 around each corner of the panel. The maximum distance between hangers is 1200 mm, optimally 600 mm, wherein the hangers are removed from the corners for 60 or 100 mm.

[0028] The panels as described above and shown in figures had a thickness of 53 mm and were used for installation of a loadbearing ceiling system for clean rooms, which were then tested in fire conditions and at a load applied on the test specimen surface was 250 kg / m 2< . The test was carried out according to SIST EN 1363-1:2020 (identical to EN 1363-1:2020) and SIST EN 1365-2:2014 (identical to EN 1365-2:2014) and the construction endured the conditions and remained intact for at least 60 minutes, which confirms that the panels and the constructed ceiling solves the technical problem.

Examples

Embodiment Construction

[0021]The fire resistant panel as shown in figure 1 comprises:

a top plate 2 made from aluminium sheet, which is chromated or RAL powder coated, a bottom plate 2' made from aluminium sheet coated with RAL powder, panel fill 4 made from mineral wool, which is provided between the top and the bottom plate, wherein the thickness of the fill is 50 mm, wherein all of the above components are glued together with a suitable glue and additionally screwed together with suitable screws 6 around the entire perimeter on side of panel and both plates 2, 2', at least every 500 mm, a side fire-resistant sealing 5, preferably an expansion tape, provided around the entire perimeter on side between said plates, a side sealing from EPDM foam 7, provided around the entire perimeter on side 3 mm from top and bottom of panel, a frame 1 made from a curved stainless steel, provided around the entire perimeter, wherein the cross-section of the frame has a shape of letter U as shown in figure 2a, preferably ...

Field of the invention

[0001] The present invention belongs to the field of construction materials, more precisely to construction panels resistant to fire. The invention relates to a fire resistant panel, a system of said panel and installation means, as well as to assemblies comprising said panels and methods of production and assembly thereof.Background of the invention and the technical problem

[0002] Fire resistant panels are used for a wide range of external façade cladding, internal partition walls, fire walls and ceilings for either leisure, commercial, industrial, hygienic and other facilities. Such panels are widely produced by various manufacturers, such as Trimo Trebnje (https: / / www.trimo-group.com / en / products / facades-and-walls / trimoterm; All Weather Insulated Panels (https: / / www.awipanels.com / product-categories / fire-panels / ), Armstrong ceilings (https: / / www.armstrongceilings.com / commercial / en / performance / fire-resistant-ceilings.html) and Durlum (https: / / www.durlum.com / en / products / metal-ceilings / functional-ceilings / dur-f30r-fire-resistant-ceilings / dur-f30r-easy-click). For example, Trimo has panels made from sheet metal and mineral wool, wherein no frame is used.

[0003] In addition to fire resistance panels used for ceilings have to exhibit suitable carrying capacity. There are several standards in this field, however, the R30 and R60 classes of the EN 13501-2:2016 relate to suitable carrying capacity under load and fire. Panels fulfilling the provisions of these two standards remain unaffected for 30 or 60 minutes, respectively, and the ceiling built with such panels does not collapse.

[0004] It is the aim of the present invention to provide panels of suitable fire-resistance according to above-identified standards as well as systems of panels and mounting (installation) means for building ceilings with suitable carrying capacity of at least 150 and up to 250 kg / m 2< . A further aim of the invention is to provide structures for ceilings and walls using said panels and installation means.Prior art

[0005] Patent application JPH10252180 relates to a fireproof wall structure of building and interior wall panel. According to this solution an exterior wall panel is provided with waterproof, wind resistant, fire shielding function and the like constituted of hard wood piece cement and the like attaches an attaching muntin to the floor beam and the like of a building unit. An interior wall panel is provided with fireproof, heat insulating and soundproof function sticking plaster boards and a rock board on both the sides of a steel frame, lower and upper horizontal muntins are attached to floor face material and ceiling face material. A fireproof non-vulcanized rubber sheet is stuck on a part attaching the exterior wall panel to a floor beam, a column and a ceiling beam. The construction of panels and their installation systems differ from the present invention.

[0006] Patent application JP2010127012 describes a partition wall structure. The partition wall structure includes a plurality of substrate panels erected between an upper rail and a lower rail respectively fixed to a ceiling and a floor face along a wall core. The substrate panel is formed by bending a long-sized steel plate into a hat shape, wherein the width of a head of the hat shape is narrower than the width of the bottom side so as to incline the side face while having a cross-section shape of a trapezoid groove in the head of the hat shape. The heads of the substrate panels are alternately arranged to both outer side directions in a zigzag way and a sound insulation material is interposed between the side faces on both ends of the adjacent substrate panels to form a partition wall substrate along a panel-wall core. A board is fixed to the head of the substrate panel by a screw or the like. The present invention differs from this disclosure in the construction of the panels.

[0007] Patent GB2509000 discloses a fire resistant structure such as a firewall or ceiling, wherein the structure comprises a number of frame units attached together to form a substructure of the fire resistant structure and a number of fire resistant panels arranged to clad the sub structure / framework so as to provide a fire-facing face of the substructure. The panels substantially cover a front face of each frame unit. The structure may be clad on the front and a rear face of the units and define a hollow zone between the front and rear faces. The panels may comprise an endothermic reacting insulating fibrous material. The frame unit may be made from steel and include a number of apertures or holes to reduce heat build up or receiving fasteners to attach one of the panels to the unit. The structure may include gaskets which substantially cover the end faces of a frame unit and located between adjacent frame units to retard / restrict heat transfer between units. Albeit this solution has a similar material for the panel frame, it has a different shape and installation means.

[0008] Patent application GB1117811 discloses a panel comprising a glass mat reinforced polyester resin containing coloured filler, aggregate and sand, a perforated asbestos panel, a metal frame made of 'L' and 'U'-section perforated steel sections and a facing of heat-insulating material e.g. mineral wool or glass-fibre quilting. Timber studding which is held in place at floor and ceiling levels and plaster board sheet nailed to the studding being applied on site. In making a unit, the perforated asbestos board with framing attached by stud and nut fastenings is partially embedded in the web resin lay up, the metallic frame removed, a layer of resin and a glass fibre mat applied to the board and the framing replaced. The panels are connected together in assembling the building by nuts and bolts inserted through adjoining parts of the metal frames, the adjoining parts being separated by a steel pad and the joints sealed by sealing, grouting or jointing material. The present invention differs in the mounting as well as frame design.

[0009] Patent FR2370835 describes a fire resistant suspended ceiling comprising insulation filled flanged panels supported by grid with tabs passing through slits along flanges. A fire resistant suspended ceiling has a support grid made of angle or channel members of stainless steel sheet, carrying dished stainless steel panels. Two angles mounted back to back have sloping arms projecting from them with parts of their top edges extending above the vertical flanges of the angles. These pass through slots through the horizontal flanges of the sides of the panels. This forms a securing system which does not require screws, bolts, clips or other extra fastenings. Each panel can be filled with a light weight refractory material such as fibre filled cement, or mineral fibre or wool.

[0010] Patent FR2349697 relates to fire resistant ceiling construction, which has several steel space trusses arranged to form rectangular space grid ceiling construction. The fire resistant space grid ceiling system comprises a number of steel space trusses arranged to form a rectangular space grid ceiling construction, the trusses having base members with opposite horizontally outwardly extending flanges and rectangularly shaped fire resistant ceiling panels supported on their opposite edges on top of the flanges in spanning relationship to adjacent base members and leaving exposed beneath it a lower portion of the base members. Rectangularly shaped, fire resistant grid protecting panels have a width the same as the width of the exposed portion of the base members and are secured to the underside of the flanges of the base members and separate elongate channel members have a vertical wall with top and bottom edges and horizontal top and bottom walls on the top and bottom edges of the vertical wall. This solution differs from the present invention.

[0011] Currently known solutions do not exhibit the required carrying capacity as defined in the above-mentioned standards, hence, the invention aims to solve these disadvantages.Description of the solution to the technical problem

[0012] The present invention addresses the problem of providing panels and systems for building ceilings as well as walls fulfilling conditions for R30 and R60 classes of the EN 13501-2:2016. The technical problem is solved as defined in the independent claim, wherein preferred embodiments are defined in dependent claims.

[0013] The fire resistant panel according to the invention comprises: a top plate, preferably made from aluminium sheet, optionally chromated or RAL powder coated particularly if used for clean rooms, a bottom plate, preferably made from aluminium sheet, optionally RAL powder coated, panel fill made from any suitable material, preferably made from mineral wool, which is provided between the top and the bottom plate, wherein the thickness of the fill is at least 50 mm to allow suitable carrying capacity of 250kg / m 2< , wherein all of the above components are glued together with a suitable glue and additionally screwed together with suitable screws around the entire perimeter on side of panel and both plates, at least every 500 mm, a side fire-resistant sealing, preferably an expansion tape, provided around the entire perimeter on side between said plates, a side sealing, preferably EPDM Foam, provided around the entire perimeter on side 3 mm from top and bottom of panel, wherein during installation of the panels silicone is provided between the panels to seal the openings and gaps between the panels to ensure water or moisture does not reach the fill material, wherein the silicon is resistant to chemicals and shows antibacterial properties, and wherein the panel further comprises: a frame made from a curved stainless steel, provided around the entire perimeter, wherein the cross-section of the frame has a shape of letter U, preferably having a thickness of the frame wall of 1 mm, and wherein said frame comprises: reinforcements at least every 600 mm and around any possible openings for installation of lights, installations, sensors and / or other elements, wherein said reinforcements are made from stainless steel, preferably shaped as the frame (U-shaped cross-section, thickness of 1 mm), wherein the reinforcements are suitably attached to the frame in any known manner, preferably with corner joints, corner joints provided at every corner, wherein said corner joints are made from curved stainless steel.

[0014] A further aspect of the invention is a system of the panel as described above and installation means for installation of panels as a hanging ceiling, wherein the installation means are aluminium holders installed in pairs around every corner and side carriers made from stainless steel arranged along each side of the panel frame.

[0015] A method of production of the fire resistant panel comprises the following steps: a) providing a first and a second aluminimum plate with preferred thickness of 1.2 mm cut in the required dimension, wherein each plate is optionally chromated or coated with RAL powder, b) providing a U-shaped frame made from bent stainless steel strips and provided with reinforcements and corner joints, c) application of glue to one surface of the first aluminium plate, d) placement of the prepared frame onto the glued surface of the first aluminium plate, e) inserting the filling material, wherein the lowermost part is filled first and then sequentially followed by each higher part, and wherein the filling material is preferably cut in three or four parts and each part is first provided with side ends and then centre parts, f) application of glue to one surface of a second aluminium plate with preferred thickness of 1.2 mm cut in the required dimension, wherein each plate is optionally chromated or coated with RAL powder, g) placement of the glued surface of the second aluminium plate on the frame, h) pressing the prepared panel in a press with spacers installed at the desired height to ensure suitable panel thickness, wherein the press operates for at least 20 minutes at pressure exponentially increasing from 0 to max 25 barscrewing together the frame and both plates with suitable screws around the entire perimeter on side of panel and both plates, at least every 500 mm, i) providing an expansion tape around the entire perimeter on side between said plates.

[0016] A plurality of panels and / or a plurality of systems as described above can be assembled into various structures, such as ceilings, hanging ceilings, ceilings for clean rooms, as well as walls, partition walls, and similar structures. The number of panels is arbitrary and depends on the size of the required structure, dimensions of the panels, and other factors. Adjusting the number of panels and / or systems is obvious to the skilled person based on the building project.

[0017] An additional aspect of the invention is also a method for installation of fire resistant panels into the assembly, wherein said method comprises the following steps: combining a plurality of panels onto a suitable carrying frame, providing and installing suitable installation means, and providing silicone in gaps between all plates, wherein the silicone is resistant to chemicals and antimicrobial, to ensure stable protection of the panel filling.

[0018] In case the assembly is a ceiling, the method for installation comprises the following steps: i. providing a plurality of panels as described above, ii. installation of aluminium hangers at dedicated positions, iii. installation of side hangers at dedicated positions, iv. providing EDPM on sides of one panel on top and bottom v. combining a plurality of panels onto a suitable carrying frame using the installed hangers, vi. providing silicone in gaps between all plates, wherein the silicone is resistant to chemicals and antimicrobial, to ensure stable protection of the panel filling.

[0019] The invention as described above solves the technical problem as tests according to standards SIST EN 13501-2:2016 have shown that the panels belong to fire-class resistance class R60. A ceiling made from said panels with installation means loaded with 250 kg / m 2< endures a fire for at least 60 minutes from below at temperatures ranging from 23 to 946 °C reached after 60 minutes without any deflections, deformations or other failure. The temperature was measured at 7 different points in the furnace used for ensuring fire-like conditions.Brief description of the drawings

[0020] The invention will be described in further detail based on exemplary embodiments and figures, which show: Figure 1A cross-section of the panel according to a possible embodiment Figure 2aFrame according to a possible embodiment Figure 2bA corner element according to a possible embodiment Figure 3Installation process for the fill material Figure 4aAluminium holder Figure 4bSide holder Detailed description of the invention

[0021] The fire resistant panel as shown in figure 1 comprises: a top plate 2 made from aluminium sheet, which is chromated or RAL powder coated, a bottom plate 2' made from aluminium sheet coated with RAL powder, panel fill 4 made from mineral wool, which is provided between the top and the bottom plate, wherein the thickness of the fill is 50 mm, wherein all of the above components are glued together with a suitable glue and additionally screwed together with suitable screws 6 around the entire perimeter on side of panel and both plates 2, 2', at least every 500 mm, a side fire-resistant sealing 5, preferably an expansion tape, provided around the entire perimeter on side between said plates, a side sealing from EPDM foam 7, provided around the entire perimeter on side 3 mm from top and bottom of panel, a frame 1 made from a curved stainless steel, provided around the entire perimeter, wherein the cross-section of the frame has a shape of letter U as shown in figure 2a, preferably having a thickness of the frame wall of 1 mm, and wherein said frame comprises: reinforcements at least every 600 mm and around any possible openings for installation of lights, installations, sensors and / or other elements, wherein said reinforcements are made from stainless steel, preferably shaped as the frame (U-shaped cross-section, thickness of 1 mm), wherein the reinforcements are suitably attached to the frame with corner joints, corner joints 3 (as shown in figure 2b) provided at every corner, wherein said corner joints are made from curved stainless steel.

[0022] The method of production of the fire resistant panel shown in figure 1 comprises the following steps: a) providing a first and a second aluminimum plate 2, 2' with thickness of 1.2 mm cut in the required dimension, wherein each plate is chromated or coated with RAL powder, b) providing a U-shaped frame 1 made from bent stainless steel strips and provided with reinforcements and corner joints, c) application of glue to one surface of the first aluminium plate 2, d) placement of the prepared frame 1 onto the glued surface of the first aluminium plate 2, e) inserting the mineral wool as the filling material 4, f) application of glue to one surface of a second aluminium plate 2' with preferred thickness of 1.2 mm cut in the required dimension, wherein each plate is chromated or coated with RAL powder, g) placement of the glued surface of the second aluminium plate 2' on the frame 1, h) pressing the prepared panel in a press with spacers installed at the desired height to ensure suitable panel thickness, wherein the press operates for at least 20 minutes at pressure exponentially increasing from 0 to max 25 bar, i) screwing together the frame and both plates with suitable screws 6 around the entire perimeter on side of panel and both plates 2, 2', at least every 500 mm, j) providing an expansion tape 7 around the entire perimeter on side between said plates.

[0023] Figure 3 shows the process of installation of the filling material in step e), wherein the lowermost part is filled first (indicated by the letter a) and then sequentially followed by each higher part indicated by letters b, c, d and e, and wherein the filling material is preferably cut in three or four parts and each part is first provided with side parts A1 and then a centre part A2.

[0024] A plurality of panels and / or a plurality of systems as described above can be assembled into various structures, such as ceilings, hanging ceilings, ceilings for clean rooms, as well as walls, partition walls, and similar structures. The number of panels is arbitrary and depends on the size of the required structure, dimensions of the panels, and other factors. Adjusting the number of panels and / or systems is obvious to the skilled person based on the building project. During installation of the panels silicone is provided between the panels to seal the openings and gaps between the panels to ensure water or moisture does not reach the fill material, wherein the silicon is resistant to chemicals and shows antibacterial properties,

[0025] The method for installation of fire resistant panels into a ceiling comprises the following steps: i. providing a plurality of panels as described above, ii. installation of aluminium hangers as shown in figure 4a at dedicated positions shown in figure 4c, iii. installation of side hangers shown in figure 4b at dedicated positions indicated in figure 4c, iv. providing EDPM on sides of one panel on top and bottom, v. combining a plurality of panels onto a suitable carrying frame using the installed hangers, and vi. providing silicone in gaps between all plates, wherein the silicone is resistant to chemicals and antimicrobial, to ensure stable protection of the panel filling.

[0026] The aluminium hanger 9 (shown in figures 1 and 4b) is shaped as a plate with a rectangular part and a semicircular part, wherein the bottom of the rectangular part is provided with holes for installation and the semicircular part is in the middle provided with an opening for installation. The side hangers 8 shown in figures 1 and 4a are similar in shape, however, they are bent for 90 degrees at approximately one half of the height of the rectangular part indicated by the arrow. A horizontal part and a vertical part are thus created, wherein the horizontal part is provided with a plurality of holes for installation and the vertical part shaped as a semi-circle is in the middle provided with an opening for installation. The expansion tape is for the installation of side hangers removed at suitable places, the hangers are then screwed in place and the expansion tape is once more provided over the hangers.

[0027] At least 8 aluminium hangers are used for each panel, at least 2 around each corner of the panel. The maximum distance between hangers is 1200 mm, optimally 600 mm, wherein the hangers are removed from the corners for 60 or 100 mm.

[0028] The panels as described above and shown in figures had a thickness of 53 mm and were used for installation of a loadbearing ceiling system for clean rooms, which were then tested in fire conditions and at a load applied on the test specimen surface was 250 kg / m 2< . The test was carried out according to SIST EN 1363-1:2020 (identical to EN 1363-1:2020) and SIST EN 1365-2:2014 (identical to EN 1365-2:2014) and the construction endured the conditions and remained intact for at least 60 minutes, which confirms that the panels and the constructed ceiling solves the technical problem.

Examples

Embodiment Construction

[0021]The fire resistant panel as shown in figure 1 comprises:

a top plate 2 made from aluminium sheet, which is chromated or RAL powder coated, a bottom plate 2' made from aluminium sheet coated with RAL powder, panel fill 4 made from mineral wool, which is provided between the top and the bottom plate, wherein the thickness of the fill is 50 mm, wherein all of the above components are glued together with a suitable glue and additionally screwed together with suitable screws 6 around the entire perimeter on side of panel and both plates 2, 2', at least every 500 mm, a side fire-resistant sealing 5, preferably an expansion tape, provided around the entire perimeter on side between said plates, a side sealing from EPDM foam 7, provided around the entire perimeter on side 3 mm from top and bottom of panel, a frame 1 made from a curved stainless steel, provided around the entire perimeter, wherein the cross-section of the frame has a shape of letter U as shown in figure 2a, preferably ...

Claims

1. A fire resistant panel comprising: - a top plate (2), - a bottom plate (2'), - panel fill (4) made from any suitable material, which is provided between the top and the bottom plate, wherein the thickness of the fill is at least 50 mm to allow suitable carrying capacity of 250kg / m2, - wherein all of the above components are glued together with a suitable glue and additionally screwed together with suitable screws (6) around the entire perimeter on side of panel and both plates, at least every 500 mm, - a side fire-resistant sealing (5) provided around the entire perimeter on side between said plates, - a side sealing (7), provided around the entire perimeter on side 3 mm from top and bottom of panel, and wherein the fire resistant panel further comprises: - a frame (1) made from a curved stainless steel, provided around the entire perimeter, wherein the cross-section of the frame (1) has a shape of letter U, preferably having a thickness of the frame wall of 1 mm, and wherein said frame (1) comprises: ∘ reinforcements at least every 600 mm and around any possible openings for installation of lights, installations, sensors and / or other elements, wherein said reinforcements are made from stainless steel, wherein the reinforcements are suitably attached to the frame in any known manner, ∘ corner joints (3) provided at every corner, wherein said corner joints (3) are made from curved stainless steel.

2. The fire resistant panel according to claim 1, wherein the top plate (2) and the bottom plate (2') are made from aluminium sheet.

3. The fire resistant panel according to claim 2, wherein the top plate (2) is chromated or RAL powder coated and the bottom plate (2') is RAL powder coated.

4. The fire resistant panel according to any of the preceding claims, wherein the panel fill (4) is mineral wool.

5. The fire resistant panel according to any of the preceding claims, wherein the side fire-resistant sealing (5) is an expansion tape.

6. The fire resistant panel according to any of the preceding claims, wherein the side sealing (7) is an EPDM Foam.

7. A system of the panel according to any of the preceding claims and installation means, wherein the installation means are aluminium holders installed in pairs around every corner and side carriers made from stainless steel arranged along each side of the panel frame.

8. The system according to the preceding claim, wherein the aluminium hanger (9) is shaped as a plate with a rectangular part and a semicircular part, wherein the bottom of the rectangular part is provided with holes for installation and the semicircular part is in the middle provided with an opening for installation, and wherein the side hanger (8) is shaped as a plate with a rectangular part and a semicircular part, wherein a bend for 90 degrees at approximately one half of the height of the rectangular part to create a horizontal part and a vertical part, wherein the horizontal part is provided with a plurality of holes for installation and the vertical part shaped as a semi-circle is in the middle provided with an opening for installation.

9. The system according to any claim from 7 to 8, wherein at least 8 aluminium hangers (9) are used for each panel, at least 2 around each corner of the panel and the maximum distance between hangers is 1200 mm.

10. An assembly comprising a plurality of panels and / or a plurality of systems according to any of the preceding claim.

11. The assembly according to the preceding claim, wherein silicone is provided between the panels to seal the openings and gaps between the panels to ensure water or moisture does not reach the fill material, wherein the silicon is resistant to chemicals and shows antibacterial properties.

12. The assembly according to any claim from 10 to 11, wherein the assembly is selected in the group of structures such as ceilings, hanging ceilings, ceilings for clean rooms, as well as walls, partition walls, and similar structures.

13. A method of production of the fire resistant panel according to any claim from 1 to 6, wherein the method comprises the following steps: a) providing a first and a second aluminimum plate (2, 2') cut in the required dimension, b) providing a U-shaped frame (1) made from bent stainless steel strips and provided with reinforcements and corner joints (3), c) application of glue to one surface of the first aluminium plate (2), d) placement of the prepared frame (1) onto the glued surface of the first aluminium plate (2), e) inserting the filling material (4), wherein the lowermost part (a) is filled first and then sequentially followed by each higher part (b, c, d, e), and wherein the filling material is preferably cut in three or four parts and each part is first provided with side parts (A1) and then a centre part (A2) installed between said side parts (A1), f) providing an expansion tape (7) around the entire perimeter on side between said plates, g) application of glue to one surface of the second aluminium plate (2') cut in the required dimension, h) placement of the glued surface of the second aluminium plate (2') on the frame (1), i) screwing together the frame and both plates with suitable screws (6) around the entire perimeter on side of panel and both plates, at least every 500 mm, j) pressing the prepared panel in a press with spacers installed at the desired height to ensure suitable panel thickness, wherein the press operates for at least 20 minutes at pressure exponentially increasing from 0 to max 25 bar.

14. A method for installation of fire resistant panels into the assembly according to any claim from 10 to 12, wherein the assembly is a wall and said method comprises the following steps: - combining a plurality of panels onto a suitable carrying frame, and - providing silicone in gaps between all plates, wherein the silicone is resistant to chemicals and antimicrobial, to ensure stable protection of the panel filling.

15. A method for installation of fire resistant panels into the assembly according to any claim from 10 to 12, wherein the assembly is a hanging ceiling and said method comprises the following steps: i. providing a plurality of panels as described above, ii. installation of aluminium hangers, iii. installation of side hangers, iv. providing EDPM on sides of one panel on top and bottom, v. combining a plurality of panels onto a suitable carrying frame using the installed hangers, and vi. providing silicone in gaps between all plates, wherein the silicone is resistant to chemicals and antimicrobial, to ensure stable protection of the panel filling.

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